TIFTON — Amidst the sudden changes caused by the COVID-19 pandemic, a simple conversation spawned a massive undertaking by one local industry to help protect its neighbors.

Most of America was forced to make critical changes as the latest and most dangerous strain of coronavirus swept through the country. American Textile Company, which has a manufacturing plant and a distribution center in Tifton and is one of the top manufacturers of bedding products in the world, found itself in need of restructuring its operations. That’s when a casual conversation between friends turned into a great idea.

“When this whole thing began, we started looking at possibilities on how we could handle our medical supplies,” said Southwell Chief Strategy and Innovation OfficerJustin Beck. “I was talking with Todd (Brey, American Textile Senior Director of Warehouse and Distribution) and he said that they may be able to help in some way. I called him the next morning to ask if he was serious. We came up with something that would be possible for them to create and financially viable for them.”

Among the hospital’s needs were mask coverings for its employees. Because some major retailers who were American Textile customers were forced to temporarily close their doors, the company’s Tifton plant had to furlough about 40 percent of its workforce, said Rick Johnson, the company’s Tifton plant manager. The local leadership team began exploring the possibilities of what it would take to produce the covers.

“After we had the idea, we worked with it for a while to see what we could come up with,” Johnson said. “We wanted to help supply them if we could because we knew the need was there. But it was also a way for us to bring our employees back in and get them back to work.”

It didn’t take long for the plan to come to fruition.

The initial conversation between Beck and Brey was on Mar. 19 and the next day, the two came up with the basics of a prototype and Southwell, which includes Tift Regional Medical Center, placed its first order.

After creating a design that included a drop filter and identifying a supplier for the elastic that is needed secure the masks around the ears, the initial supply was delivered to Tift Regional. From there, word spread quickly.

“It’s all been word of mouth,” Johnson said. “We haven’t marketed it or anything like that. But when word got out, it got out fast.”

Approximately 2,000 masks were originally produced for TRMC and before long, the company had orders for nearly a half million masks. The company’s home office in Pennsylvania liked the idea and orders began coming in from hospitals in that area and from the Dallas area, where ATC also has a manufacturing plant.

Other businesses, such as hardware stores from around South Georgia, began placing orders and the quick production learning curve got quicker.

Johnson said the Tifton plant is producing around 2,000 masks per day and the rate is increasing. Also, the company’s plants in Pennsylvania, Dallas, Salt Lake City, and El Salvador are also producing masks for a total of nearly 8,000 per day. Johnson said the company’s goal is to produce 1 million masks.

Beck said the masks are used as covers for the N-95 masks hospital employees wear each day. The coverings help the actual masks stay cleaner longer while the coverings can be laundered and sterilized and used again. Beck also said this kind of partnership may be what is needed in the long run as well.

“The great thing about working with the folks at American Textile is that I think we’re all going to be looking at more locally produced things in the future,” he said. “I think this pandemic will cause us to consider that we won’t have the global economy like we used to and we need to consider how to work together more.”

Lance Ruttenberg, American Textile’s President and CEO, said he was glad that his company was able to assist in the effort, and added that he is not surprised at the teamwork taking place in Tifton.

“The Tifton community has always come together to solve their challenges, and I am proud of the partnership that is bringing these critical masks to the people who need them most,” he said. “American Textile is honored to play a role in helping the Tifton community address the COVID-19 public health crisis.”

Brian Marlowe, the President and CEO of the Tifton-Tift County Chamber of Commerce and the Tift County Development Authority, said American Textile’s effort does not surprise him at all.

“American Textile Company and its employees always answer the call,” he said. “Whether they are responding to a crisis or volunteering their time, effort, and resources in our community, they lead by example. We are grateful for their partnership.”